Ribbon liquefier and method of use in extrusion-based digital manufacturing systems

ABSTRACT

A ribbon liquefier comprising an outer liquefier portion configured to receive thermal energy from a heat transfer component, and a channel at least partially defined by the outer liquefier portion, where the channel has dimensions that are configured to receive the ribbon filament, and where the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel are further configured to conform the melt flow from an axially-asymmetric flow to a substantially axially-symmetric flow in an extrusion tip connected to the ribbon liquefier.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. patent application Ser. No.14/560,480, filed Dec. 4, 2014, which is a continuation of U.S. patentapplication Ser. No. 13/867,366, filed Apr. 22, 2013 and published asU.S. Pat. No. 8,926,882, which is a divisional of U.S. patentapplication Ser. No. 12/612,329, filed on Nov. 4, 2009 and published asU.S. Pat. No. 8,439,665, and which claims priority to U.S. ProvisionalPatent Application No. 61/247,068, filed on Sep. 30, 2009.

Reference is hereby made to U.S. patent application Ser. No. 12/612,333,filed on Nov. 4, 2009, which issued as U.S. Pat. No. 8,221,669, andwhich claims priority to U.S. Provisional Patent Application No.61/247,067, filed on Sep. 30, 2009. Reference is also hereby made toU.S. patent application Ser. No. 13/530,191, filed on Jun. 22, 2012,which is a divisional of U.S. patent application Ser. No. 12/612,333.

Reference is also hereby made to U.S. patent application Ser. No.12/612,342, filed on Nov. 4, 2009, which issued as U.S. Pat. No.8,236,227, and which claims priority to U.S. Provisional PatentApplication No. 61/247,078, filed on Sep. 30, 2009.

BACKGROUND

The present disclosure relates to direct digital manufacturing systemsfor building three-dimensional (3D) models. In particular, the presentinvention relates to extrusion head liquefiers for use inextrusion-based digital manufacturing systems.

An extrusion-based digital manufacturing system (e.g., fused depositionmodeling systems developed by Stratasys, Inc., Eden Prairie, Minn.) isused to build a 3D model from a digital representation of the 3D modelin a layer-by-layer manner by extruding a flowable consumable modelingmaterial. The modeling material is extruded through an extrusion tipcarried by an extrusion head, and is deposited as a sequence of roads ona substrate in an x-y plane. The extruded modeling material fuses topreviously deposited modeling material, and solidifies upon a drop intemperature. The position of the extrusion head relative to thesubstrate is then incremented along a z-axis (perpendicular to the x-yplane), and the process is then repeated to form a 3D model resemblingthe digital representation.

Movement of the extrusion head with respect to the substrate isperformed under computer control, in accordance with build data thatrepresents the 3D model. The build data is obtained by initially slicingthe digital representation of the 3D model into multiple horizontallysliced layers. Then, for each sliced layer, the host computer generatesa build path for depositing roads of modeling material to form the 3Dmodel.

In fabricating 3D models by depositing layers of a modeling material,supporting layers or structures are typically built underneathoverhanging portions or in cavities of objects under construction, whichare not supported by the modeling material itself. A support structuremay be built utilizing the same deposition techniques by which themodeling material is deposited. The host computer generates additionalgeometry acting as a support structure for the overhanging or free-spacesegments of the 3D model being formed. Consumable support material isthen deposited from a second nozzle pursuant to the generated geometryduring the build process. The support material adheres to the modelingmaterial during fabrication, and is removable from the completed 3Dmodel when the build process is complete.

SUMMARY

An aspect of the present disclosure is directed to a ribbon liquefierfor use in an extrusion-based digital manufacturing system having adrive mechanism and a heat transfer component. The ribbon liquefierincludes an outer liquefier portion configured to receive thermal energyfrom the heat transfer component, and a channel at least partiallydefined by the outer liquefier portion. The channel has dimensions thatare configured to receive a ribbon filament, wherein the ribbonliquefier is configured to melt the ribbon filament received in thechannel to at least an extrudable state with the received thermal energyto provide a melt flow. Additionally, the dimensions of the channel arefurther configured to conform the melt flow from an axially-asymmetricflow to a substantially axially-symmetric flow in an extrusion tipconnected to the ribbon liquefier.

Another aspect of the present disclosure is directed to a ribbonliquefier for use in an extrusion-based digital manufacturing systemhaving a drive mechanism and a heat transfer component, where the ribbonliquefier includes an outer tube having an exterior surface and aninterior surface, and where the exterior surface of the outer tube isconfigured to engage with the heat transfer component. The ribbonliquefier also includes a core portion disposed within the outer tubeand having an exterior surface, and a shim component disposed betweenthe outer tube and the core portion. The shim component has a gap thatextends along a longitudinal length of the shim component, where the gapdefines a channel between the interior surface of the outer tube and theexterior surface of the core portion. The channel has dimensions thatare configured to receive a ribbon filament, where the exterior surfaceof the core portion is configured to provide backing support to theribbon filament when the drive mechanism is engaged with the ribbonfilament.

Another aspect of the present disclosure is directed to a method forbuilding a three-dimensional model in an extrusion-based digitalmanufacturing system. The method includes driving a ribbon filamentthrough a channel of a ribbon liquefier, where the ribbon liquefierfurther includes an outer liquefier portion that at least partiallydefines the channel. The method also includes melting the ribbonfilament in the channel to at least an extrudable state to provide amelt flow, where the dimensions of the channel conform the melt flow toan axially-asymmetric flow, and extruding the melt flow from anextrusion tip of the ribbon liquefier, where the melt flow has asubstantially axially-symmetric flow in the extrusion tip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an extrusion-based digital manufacturingsystem that includes ribbon liquefiers for melting received ribbonfilaments of modeling and support materials.

FIG. 2 is a top perspective view of a subassembly of the extrusion head,which includes a ribbon liquefier engaged with a drive mechanism and athermal block.

FIG. 3 is a perspective view of the ribbon liquefier, which includes aported outer tube.

FIG. 4A is a sectional view of section 4A-4A taken in FIG. 3.

FIG. 4B is a sectional view of section 4B-4B taken in FIG. 3.

FIG. 4C is a sectional view of section 4C-4C taken in FIG. 3.

FIG. 5 is an exploded perspective view of the ribbon liquefier.

FIG. 6 is a side view of the ribbon liquefier in use with a drivemechanism having a rotatable pulley for receiving, melting, andextruding a ribbon filament.

FIG. 7 is a side view of the ribbon liquefier in use with an alternativedrive mechanism having a threaded rotatable shaft mechanism forreceiving, melting, and extruding a ribbon filament.

FIG. 8A is a sectional view of a ribbon filament in a relaxed,non-flexed state.

FIG. 8B is a sectional view of the ribbon filament in a flexed state.

FIG. 9 is a perspective view of a first alternative ribbon liquefier,which includes an open-top arrangement.

FIG. 10 is an alternative sectional view of section 4C-4C, illustratinga second alternative ribbon liquefier, which includes a non-arcuatechannel for receiving a ribbon filament.

DETAILED DESCRIPTION

The present disclosure is directed to a ribbon liquefier for use inextrusion-based digital manufacturing systems, where the ribbonliquefier is configured to receive ribbon filaments of modeling and/orsupport materials. As used herein, the term “ribbon filament” refers toa strand of a material having a non-cylindrical geometry, such as arectangular and/or a film-like cross-section. This is in comparison to a“cylindrical filament”, which has a cross-sectional profile that iscircular. The use of the ribbon filament in combination with the ribbonliquefier allows the modeling and support materials to be melted andextruded with reduced response times. This is beneficial for improvingdepositional accuracies and reducing build times, thereby increasingprocess efficiencies for building 3D models and corresponding supportstructures with the ribbon liquefier.

FIG. 1 is a front view of system 10, which is an extrusion-based digitalmanufacturing system that includes build chamber 12, platen 14, gantry16, extrusion head 18, and supply sources 20 and 22, where extrusionhead 18 may include one or more ribbon liquefiers (not shown in FIG. 1)for melting successive portions of ribbon filaments (not shown inFIG. 1) during a build operation with system 10. Suitableextrusion-based digital manufacturing systems for system 10 includefused deposition modeling systems developed by Stratasys, Inc., EdenPrairie, Minn.

Build chamber 12 is an enclosed environment that contains platen 14,gantry 16, and extrusion head 18 for building a 3D model (referred to as3D model 24) and a corresponding support structure (referred to assupport structure 26). Platen 14 is a platform on which 3D model 24 andsupport structure 26 are built, and moves along a vertical z-axis basedon signals provided from a computer-operated controller (referred to ascontroller 28). Gantry 16 is a guide rail system configured to moveextrusion head 18 in a horizontal x-y plane within build chamber 12based on signals provided from controller 28. The horizontal x-y planeis a plane defined by an x-axis and a y-axis (not shown in FIG. 1),where the x-axis, the y-axis, and the z-axis are orthogonal to eachother. In an alternative embodiment, platen 14 may be configured to movein the horizontal x-y plane within build chamber 12, and extrusion head18 may be configured to move along the z-axis. Other similararrangements may also be used such that one or both of platen 14 andextrusion head 18 are moveable relative to each other.

Extrusion head 18 is supported by gantry 16 for building 3D model 24 andsupport structure 26 on platen 14 in a layer-by-layer manner, based onsignals provided from controller 28. Extrusion head 18 includessubassemblies 30 and 32, each of which desirably includes a ribbonliquefier of the present disclosure. Accordingly, subassembly 30 isconfigured to receive and melt successive portions of a modelingmaterial ribbon filament with a first ribbon liquefier (not shown inFIG. 1), and subassembly 32 is configured to receive and melt successiveportions of a support material ribbon filament with a second ribbonliquefier (not shown in FIG. 1).

The modeling material ribbon filament may be provided to subassembly 30from supply source 20 through pathway 34. Similarly, the supportmaterial ribbon filament may be provided to subassembly 32 from supplysource 22 through pathway 36. System 10 may also include additionaldrive mechanisms (not shown) configured to assist in feeding the ribbonfilaments from supply sources 20 and 22 to subassemblies 30 and 32.Supply sources 20 and 22 are sources (e.g., spooled containers) for themodeling and support ribbon filaments, and are desirably retained at aremote location from build chamber 12. Suitable assemblies for supplysources 20 and 22 are disclosed in Swanson et al., U.S. Pat. No.6,923,634; Comb et al., U.S. Pat. No. 7,122,246; and Taatjes et al, U.S.Pat. Nos. 7,938,351 and 7,938,356.

During a build operation, gantry 16 moves extrusion head 18 around inthe horizontal x-y plane within build chamber 12, and the ribbonfilaments are fed to subassemblies 30 and 32. Subassembly 30 thermallymelts the successive portions of the received modeling material ribbonfilament, thereby allowing the molten material to be extruded to build3D model 24. Similarly, subassembly 32 thermally melts the successiveportions of the support material ribbon filament, thereby allowing themolten material to be extruded to build support structure 26. Theupstream, unmelted portions of the ribbon filaments may each function asa piston with a viscosity-pump action to extrude the molten material outof the respective subassemblies 30 and 32.

The extruded modeling and support materials are then deposited ontoplaten 14 to build 3D model 24 and support structure 26 using alayer-based additive technique. Support structure 26 is desirablydeposited to provide vertical support along the z-axis for overhangingregions of the layers of 3D model 24. This allows 3D model 24 to bebuilt with a variety of geometries. After the build operation iscomplete, the resulting 3D model 24/support structure 26 may be removedfrom build chamber 12, and support structure 26 may be removed from 3Dmodel 24.

FIG. 2 is a top perspective view of subassembly 30 of extrusion head 18,where the following discussion of subassembly 30 is equally applicableto subassembly 32 (shown in FIG. 1). As shown in FIG. 2, subassembly 30includes ribbon liquefier 38, thermal block 40, and drive mechanism 42,where drive mechanism 42 feeds successive portions of ribbon filament 44through ribbon liquefier 38. In the shown embodiment, ribbon liquefier38 includes a series of annular tubes extending between top end 48 andbottom end 50. Top end 48 and bottom end 50 are opposing ends of ribbonliquefier 38 along longitudinal axis 46, where top end 48 is configuredto receive ribbon filament 44 in a flexed state. When subassembly 30 ismounted in system 10 (shown in FIG. 1) longitudinal axis 46 correspondsto the vertical z-axis. As shown in FIG. 2, the annular tubes of ribbonliquefier 38 extend through drive mechanism 42 and thermal block 40along longitudinal axis 46.

Ribbon liquefier 38 also includes extrusion tip 52, which is asmall-diameter tip that is located at a bottom end 50 and is configuredto extrude the molten material of ribbon filament 44 with a desired roadwidth. In one embodiment, extrusion tip 52 is removably securable to oneor more of the annular tubes at bottom end 50, thereby allowing multipleextrusion tips 52 to be interchangeably used. Examples of suitable innertip diameters for extrusion tip 52 range from about 125 micrometers(about 0.005 inches) to about 510 micrometers (about 0.020 inches).

Thermal block 40 is a heat transfer component that extends around atleast a portion of ribbon liquefier 38 and is configured to conduct heatto ribbon liquefier 38 and the received ribbon filament 44. Examples ofsuitable heat transfer components for thermal block 40 include thosedisclosed in Swanson et al., U.S. Pat. No. 6,004,124; Comb, U.S. Pat.No. 6,547,995; LaBossiere et al., U.S. Pat. No. 7,604,470; andBatchelder et al., U.S. Pat. No. 7,897,074. In alternative embodiments,thermal block 40 may be replaced with a variety of different heattransfer components that generate thermal gradients along longitudinalaxis 46.

Drive mechanism 42 includes support plate 54, base block 56, and pulley58, where pulley 58 is rotatably secured between support plate 54 andbase block 56. Support plate 54 and base block 56 are support componentsof drive mechanism 42, and one or both of support plate 54 and baseblock 56 may be secured to extrusion head 18 (shown in FIG. 1). Pulley58 is a rotatable component that drives successive portions of ribbonfilament 44 through ribbon liquefier 38 with the use of aninternally-threaded surface (not shown in FIG. 2). Examples of suitablefilament drive mechanisms for drive mechanism 42 include those disclosedin Batchelder et al., U.S. Pat. Nos. 7,896,209 and 7,897,074.

During a build operation in system 10 (shown in FIG. 1), ribbon filament44 is desirably flexed to a flexed state for alignment with ribbonliquefier 38. The flexed ribbon filament 44 may then be loaded intoribbon liquefier 38 at top end 48 (represented by arrow 60) to engagewith the internally-threaded surface of pulley 58. Pulley 58 is thenrotated (represented by arrow 62) based on signals provided fromcontroller 28 (shown in FIG. 1). The rotation of pulley 58correspondingly rotates the internally-threaded surface of pulley 58,which drives successive portions of ribbon filament 44 through ribbonliquefier 38.

As ribbon filament 44 passes through ribbon liquefier 38, the thermalgradient generated by thermal block 40 melts the material of ribbonfilament 44 within ribbon liquefier 38 to at least an extrudable state.The upstream, unmelted portion of ribbon filament 44 being driven bydrive mechanism 42 functions as a piston with a viscosity pump acting onthe molten material between the unmelted portion the walls of ribbonliquefier 38, thereby extruding the molten material out of extrusion tip52. The extruded material may then be deposited as roads to form 3Dmodel 24 in a layer-by-layer manner.

As further shown in FIG. 2, top end 48 of ribbon liquefier 38 is locatedat an upstream position along longitudinal axis 46 relative to drivemechanism 42. As such, ribbon filament 44 may enter ribbon liquefier 38at an inlet region (referred to as inlet region 64) prior to engagingwith drive mechanism 42, and may be continuously supported by ribbonliquefier 38 during and after the engagement with drive mechanism 42.This reduces the risk of interrupting a build operation with extrusionhead 18, and may allow higher driving forces to be attained becauseribbon filament 44 is supported from buckling.

The cross-sectional profiles of ribbon liquefier 38 and ribbon filament44 allow ribbon filament 44 to be melted and extruded from extrusionhead 18 with reduced response times compared to cylindrical filamentsand liquefiers. As discussed in U.S. Pat. No. 8,221,669, it is believedthat the cross-sectional profiles of ribbon liquefier 38 and ribbonfilament 44 effectively remove the core that is associated with acylindrical filament having a circular cross-section. This allows ribbonfilament 44 to be melted and extruded from extrusion head 18 withreduced response times, which can correspondingly increase processefficiencies in system 10 for building 3D model 24 and/or supportstructure 26.

For example, reduced response times may increase the accuracy of startand stop locations for deposited roads of modeling and supportmaterials. During a build operation to form a layer of a 3D model (e.g.,3D model 24), an extrusion head (e.g., extrusion head 18) is moved in ahorizontal x-y plane and deposits a molten modeling material. After agiven deposition pattern is completed, the extrusion head stopsdepositing the modeling material. This is accomplished by stopping thefilament from being fed into the liquefier of the extrusion head,thereby halting the viscosity-pump action of the filament.

However, the response time between when the extrusion head stops feedingthe filament to the liquefier and when the modeling material actuallystops extruding from the extrusion head is not instantaneous. Instead,there is a delay that is based on factors such as the thermal propertiesof the liquefier, the composition of the filament, and, as discussedbelow, the cross-sectional profile of the filament and liquefierchannel. Similarly, there is also a response time delay associated withthe transition from a zero-flow state to a steady-state flow. Liquefiersand filaments that require large response times increase these delays,thereby potentially decreasing depositional accuracies. Reducing theresponse times, however, can improve the aesthetic and structuralqualities of the resulting 3D model, particularly when building 3Dmodels containing fine features.

For example, a reduced response time for system 10 can gate theacceleration of gantry 16 at suitable locations near the depositionstart and stop points. This can increase the ability to hide the seamsof each layer, which can increase part quality. Additionally, theresponse time determines how far gantry 16 can deviate from a constanttangential velocity as gantry 16 travels around a corner in the x-yplane. As a result, a reduced response time allows extrusion head 18 toachieve greater cornering accelerations and decelerations. This canreduce the production times required to build 3D models and supportstructures, much in the same manner as the cornering capabilities of arace car are important for reducing an overall race time.

FIG. 3 is an expanded perspective view of ribbon liquefier 38, whichincludes outer tube 66, core tube 68, and shim component 70. As shown,shim component 70 is disposed circumferentially between outer tube 66and core tube 68, such that outer tube 66, core tube 68, and shimcomponent 70 define channel 72 extending along longitudinal axis 46between top end 48 and bottom end 50. As discussed below, channel 72 isthe portion of ribbon liquefier 38 that receives ribbon filament 44(shown in FIG. 2).

Outer tube 66, core tube 68, and shim component 70 may each befabricated from a variety of materials, which are desirably capable ofwithstanding the thermal energy from thermal block 40 and any elevatedtemperature of build chamber 12 (shown in FIG. 1). Suitable materialsfor fabricating each of outer tube 66, core tube 68, and shim component70 include thermally-conductive, metallic materials, such as stainlesssteel.

Outer tube 66 is an outer liquefier portion of ribbon liquefier 38 thatincludes exterior surface 74, which extends along longitudinal axis 46between top end 48 and bottom end 50. In the shown embodiment, outertube 66 has a cylindrical cross-section. In alternative embodiments,outer tube 66 may be replaced with tubes having differentcross-sectional geometries. Accordingly, as used herein, the term “tube”includes a variety of hollow geometries, such as cylindrical geometries,elliptical geometries, polygonal geometries (e.g., rectangular andsquare geometries), axially-tapered geometries, and the like. Exteriorsurface 74 is the portion of outer tube 66 that contacts thermal block40 for generating a thermal gradient along ribbon liquefier 38. Thethermal gradient creates a temperature profile in ribbon filament 44along longitudinal axis 46, which melts successive portions of ribbonfilament 44 as ribbon filament 44 is driven through ribbon liquefier 38.

As further shown in FIG. 3, outer tube 66 also includes port 76 andheated length 78. Port 76 is a lateral opening through outer tube 66between inlet region 64 and heated length 78. As discussed below, port76 allows pulley 58 (shown in FIG. 2) to engage with ribbon filament 44after ribbon filament 44 is loaded into channel 72. This allows theinternally-threaded surface of pulley 58 to drive ribbon filament 44toward heated length 78.

The dimensions of port 76 may vary depending on the dimensions of ribbonfilament 44 and on the drive mechanism used (e.g., drive mechanism 42).For example, the length of port 76 along longitudinal axis 46 (referredto as port length 80) may vary depending on the dimensions of theinternally-threaded surface of pulley 58. Examples of suitable lengthsfor port length 80 range from about 1.25 millimeters (about 0.05 inches)to about 25.0 millimeters (about 1.0 inch), with particularly suitablelengths 64 ranging from about 5.1 millimeters (about 0.2 inches) toabout 12.7 millimeters (about 0.5 inches).

Heated length 78 is a region along outer tube 66 in which the thermalgradient generated by thermal block 40 (shown in FIG. 2) exists formelting ribbon filament 44. Heated length 78 desirably extends along thelongitudinal length of outer tube 66 below port 76, thereby preventingribbon filament 44 from melting while engaged with pulley 58.Accordingly, heated length 78 desirably extends along the longitudinallength of outer tube 66 between port 76 and bottom end 50/extrusion tip52. In one embodiment, extrusion head 18 (shown in FIG. 1) may alsoinclude an airflow manifold (not shown) configured to direct cooling airtoward top end 48 and/or port 76 to further reduce the risk of thethermal gradient affecting ribbon filament 44 at port 76.

Suitable dimensions for heated length 78 to exist, between port 76 andbottom end 50 (referred to as length 82), may vary depending on the heattransfer properties of thermal block 40, the thickness and material ofouter tube 66, and the thickness, material, and drive rate of ribbonfilament 44. Examples of suitable lengths for length 82 range from about13 millimeters (about 0.5 inch) to about 130 millimeters (about 5.0inches), with particularly suitable lengths ranging from about 25millimeters (about 1.0 inch) to about 51 millimeters (about 2.0 inches).

Core tube 68 is a core portion of ribbon liquefier 38 and is disposedwithin outer tube 66 between top end 48 and bottom end 50. As shown,core tube 68 includes exterior surface 84, which is exposed at port 76.While shown as a hollow tube, a variety of alternative core portions maybe used in lieu of core tube 68, such as non-hollow, filled coreportions. These embodiments may be beneficial to strengthen the lateralsupport for ribbon filament 44 when engaged with drive mechanism 42.Nonetheless, the use of a hollow tube (e.g., core tube 68) for the coreportion is beneficial for reducing the weight of ribbon liquefier 38,and may allow electrical and/or thermal components to be retainedtherein. For example, one or more additional heat transfer components(not shown) may be secured within core tube 68 to assist thermal block40 in generating a thermal gradient along longitudinal axis 46. In theseembodiments, core tube 68 desirably has a wall thickness that issufficient to support ribbon filament 44 when engaged with drivemechanism 42 (e.g., at least about 0.25 millimeters (about 0.01inches)). Furthermore, as discussed above for outer tube 66, core tube68 may also be replaced with tubes having different cross-sectionalgeometries.

Shim component 70 is a C-shaped component secured between outer tube 66and core tube 68, and also extends between top end 48 and bottom end 50.As discussed below, shim component 70 includes a gap extending betweentop end 48 and bottom end 50, and is substantially aligned with port 76.The gap of shim component 70 between outer tube 66 and core tube 68defines channel 72, which has an arcuate cross-section and issubstantially aligned with port 76. This arrangement allows drivemechanism 42 to engage ribbon filament 44 while ribbon filament 44extends through channel 72, where the portion of exterior surface 84 atport 76 may function as a lateral backing support for ribbon filament 44when engaged with drive mechanism 42.

During the manufacture of subassembly 30 (shown in FIGS. 1 and 2),ribbon liquefier 38 may be secured within thermal block 40 such thatport 76 extends above thermal block 40. As discussed above, thisdesirably restricts heated length 78 to a location below port 76. Ribbonliquefier 38 may be secured within thermal block 40 in a variety ofmanners. In one embodiment, thermal block 40 may be separated (orotherwise opened) to allow direct access within thermal block 40. Ribbonliquefier 38 may then be inserted within thermal block 40, and thermalblock 40 may be reassembled (or otherwise closed) to provide goodthermally-conductive contact between outer tube 66 of ribbon liquefier38 and thermal block 40. Extrusion tip 52 may also be secured to outertube 66 at bottom end 50. Ribbon liquefier 38 may also be secured todrive mechanism 42 in a manner that allows the internally-threadedsurface of pulley 58 to engage with ribbon liquefier 38 at port 76.

During operation, the dimensions of channel 72 are configured to conformthe melt flow of the molten material of ribbon filament 44 to anaxially-asymmetric flow, which in this example, is an arcuate-patternedflow. Upon reaching extrusion tip 52, however, this melt flow changes toa substantially axially-symmetric flow for extrusion. This is incontrast to a cylindrical liquefier, in which a melt flow remains as anaxially-symmetric flow in the cylindrical liquefier and in the extrusiontip.

FIGS. 4A-4C are sectional views of sections 4A-4A, 4B-4B, and 4C-4Crespectively taken in FIG. 3. The section shown in FIG. 4A illustratesinlet region 64. As shown, outer tube 66 further includes interiorsurface 86, where interior surface 86 defines an inner diameter of outertube 66 (referred to as inner diameter 86 d). Examples of suitableaverage diameters for inner diameter 86 d range from about 3.8millimeters (about 0.15 inches) to about 10.2 millimeters (about 0.40inches), with particularly suitable diameters ranging from about 5.1millimeters (about 0.20 inches) to about 7.6 millimeters (about 0.30inches).

Correspondingly, exterior surface 74 defines an outer diameter of outertube 66 (referred to as outer diameter 74 d). Outer diameter 74 d mayvary depending on the wall thickness of outer tube 66 and inner diameter86 d, and desirably allows outer tube 66 to be inserted through supportplate 54, pulley 58, and base block 56 of drive mechanism 42 (shown inFIG. 2), and to be retained by one or both of support plate 54 and baseblock 56. Accordingly, examples of suitable average wall thicknesses forliquefier tube 66 (i.e., the difference between outer diameter 74 d andinner diameter 86 d) range from about 1.3 millimeters (about 0.05inches) to about 7.6 millimeters (about 0.30 inches), with particularlysuitable thicknesses ranging from about 2.5 millimeters (about 0.10inches) to about 5.1 millimeters (about 0.20 inches).

As further shown in FIG. 4A, exterior surface 84 of core tube 68 definesan outer diameter of core tube 68 (referred to as outer diameter 84 d).The difference between inner diameter 86 d of outer tube 66 and outerdiameter 84 d of core tube 68 accordingly defines the thickness ofchannel 72 (referred to as channel thickness 88). Examples of suitabledimensions for channel thickness 88 range from about 0.25 millimeters(about 0.01 inches) to about 2.5 millimeters (about 0.10 inches), withparticularly suitable thicknesses ranging from about 0.51 millimeters(about 0.02 inches) to about 2.0 millimeters (about 0.08 inches), andwith even more particularly suitable thicknesses ranging from about 0.76millimeters (about 0.03 inches) to about 1.8 millimeters (about 0.07inches). Because channel 72 is defined in part by the gap in shimcomponent 70, shim component 70 also has a thickness corresponding tochannel thickness 88.

In the shown embodiment, channel 72 also has an arcuate width extendingacross the gap in shim component 70, which desirably corresponds to thedimensions of ribbon filament 44 in a flexed state. The arcuate widthmay be measured by an angle (referred to as angle α) from aradially-concentric point of channel 72, such as shown in FIG. 4A.Examples of suitable angles for angle α range from about 30 degrees toabout 180 degrees, with particularly suitable angles ranging from about45 degrees to about 130 degrees, and with even more particularlysuitable angles ranging from about 60 degrees to about 90 degrees.

Alternatively, the width of channel 72 may be measured based on arectangular geometry rather than its arcuate geometry. Examples ofsuitable dimensions for the width of channel 72 range from about 1.0millimeter (about 0.04 inches) to about 12.7 millimeters (about 0.50inches), with particularly suitable widths ranging from about 3.0millimeters (about 0.12 inches) to about 10.1 millimeters (about 0.40inches), and with even more particularly suitable widths ranging fromabout 3.8 millimeters (about 0.15 inches) to about 6.4 millimeters(about 0.25 inches).

As discussed above, the aspect ratios of ribbon liquefier 38 and ribbonfilament 44 may be selected to effectively removing a core that isassociated with a filament feedstock having a circular cross-section.This allows the ribbon liquefier 38 to attain reduced response timescompared to cylindrical liquefiers having the same volumetric flowrates. In particular, as disclosed in U.S. Pat. No. 8,221,669, highaspect ratios are particularly suitable for reducing response rates.Accordingly, examples of suitable aspect ratios of the width of channel72 to channel thickness 88 include aspect ratios of about 2:1 orgreater.

In some situations, aspect ratios that are too large may placeundesirably high loads on outer surface 84 and ribbon filament 44, andmay also increase the frictional drag between ribbon filament 44 andchannel 72. Accordingly, examples of particularly suitable aspect ratiosof the width of channel 72 to channel thickness 88 range from about2.5:1 to about 20:1, with more particularly suitable aspect ratiosranging from about 3:1 to about 10:1, and with even more particularlysuitable aspect ratios ranging from about 3:1 to about 8:1.

An additional distinction from cylindrical liquefiers can be made bycomparing the dimensions in which thermal energy diffuses within thegiven liquefier. Thermal energy is diffused to cylindrical filamentsreceived within cylindrical liquefiers in two dimensions, where about50% of the thermal energy is diffused along a first dimension (e.g.,along the x-axis) and about 50% of the thermal energy diffused along asecond dimension (e.g., along the y-axis). In comparison, however, themajority of the thermal energy is diffused to ribbon filament 44 inliquefier 38 along only one dimension. In fact, this single dimensiondiffusion increases with the aspect ratio of ribbon filament 44 andliquefier 38. Accordingly, for the above-discussed suitable aspectratios, at least about 60% of the thermal energy is diffused only in onedimension, more desirably at least about 65% of the thermal energy isdiffused only in one dimension, and even more desirably at least about70% of the thermal energy is diffused only in one dimension.

In one embodiment, exterior surface 84 of core tube 68 and/or interiorsurface 86 of outer tube 66 may be smoothed and/or polished to reducesliding friction of ribbon filament 44. In an additional embodiment, oneor more portions of exterior surface 84 and interior surface 86 at inletregion 64 may include a low-surface energy coating to further reducefriction with ribbon filament 44. Suitable coating materials includefluorinated polymers (e.g., polytetrafluoroethenes, fluorinated ethylenepropylenes, and perfluoroalkoxy polymers), diamond-like carbonmaterials, and combinations thereof.

The section shown in FIG. 4B illustrates port 76, which, in the shownembodiment has an arcuate width that is substantially aligned withchannel 72. In alternative embodiments, the arcuate width of channel 72may be greater than that of port 76. The angle of the arcuate width ofport 76 (referred to as angle β) may vary depending on the engagementbetween the internally-threaded surface of the pulley 58 and on thearcuate width of channel 72. Accordingly, examples of suitable anglesfor angle β range from about 30 degrees to about 180 degrees, withparticularly suitable angles ranging from about 45 degrees to about 130degrees, and with even more particularly suitable angles ranging fromabout 60 degrees to about 90 degrees.

The section shown in FIG. 4C illustrates heated length 78, where, in theshown embodiment, channel 72 at heated length 78 has the same dimensionsas at inlet region 64 (shown in FIG. 4A) and at port 76 (shone in FIG.4B). Thus, in this embodiment, channel 72 has the substantially samedimensions along longitudinal axis 46 between top end 48 and bottom end50. In alternative embodiments, the thickness (referred to as channelthickness 89) and/or the arcuate width of channel 72 may vary alonglongitudinal axis 46. For example, one or both of channel thickness 89and the width of channel 72 may gradually decrease when travelingdownward along heated length 78 toward bottom end 50.

Examples of suitable average thicknesses for channel thickness 89include those discussed above for channel thickness 88 (shown in FIG.4A), where channel thickness 89 may be the same as channel thickness 88or may gradually decrease along longitudinal length 46 toward bottom end50. Similarly, examples of suitable angles for the arcuate width(referred to as angle θ) include those discussed above for angle α(shown in FIG. 4A), where angle θ may be the same as angle α or maygradually decrease along longitudinal length 46 toward bottom end 50.

FIG. 5 is an exploded perspective view of ribbon liquefier 38,illustrating a technique for manufacturing ribbon liquefier 38. Ribbonliquefier 38 may be manufactured by initially inserting shim component70 around exterior surface 84 of core tube 68 (e.g., sliding core tube68 into shim component 70, as shown by arrow 90). Shim component 70 maybe secured around exterior surface 84 in a variety of manners, such aswith a friction fitting, adhesive compounds, and/or welding operations.

Shim component 70 includes a gap (referred to as gap 92) that partiallydefines channel 72, as discussed above. Additionally, the portion ofshim component 70 at bottom end 50 of ribbon liquefier 38 is tapered tofit within extrusion tip 52, where gap 92 may also correspondinglydecrease in arcuate width. Core tube 68 also includes conical tip 94 atbottom end 50 of ribbon liquefier 38, which is also tapered to fitwithin shim component 70 and extrusion tip 52. Conical tip 94 is alsodesirably a sealed tip to prevent the molten material from back flowinginto the hollow bore region of core tube 68.

The assembled core tube 68/shim component 70 may then be inserted intoouter tube 66 (shown by arrow 96), and gap 92 is desirably aligned withport 76. Outer tube 66 may be secured around core tube 68/shim component70 in a variety of manners, such as with a friction fitting, adhesivecompounds, and/or welding operations. This provides channel 72, which isdefined by exterior surface 84 of core tube 68, interior surface 86 ofouter tube 66, and shim component 70 at gap 92, and extends from top end48 to extrusion tip 52 at bottom end 50.

Outer tube 66, core tube 68, shim component 70 may alternatively beassembled in a variety of manners. For example, shim component 70 mayinserted within outer tube 66 prior to the insertion of core tube 68within outer tube 66. Furthermore, core tube 68 may initially beinserted within outer tube 66, and shim component 70 may then beinserted between outer tube 66 and core tube 68. Additionally, extrusiontip 52 may be removably secured to outer tube 66 at bottom end 50 (e.g.,screwed onto outer tube 66). In an additional alternative embodiment,one or more of outer tube 66, core tube 68, shim component 70 may beintegrally formed (e.g., extruded or cast) together rather than asseparate components that are subsequently assembled. The resultingribbon liquefier 38 may then be installed in subassembly 30 of extrusionhead 18, as discussed above.

As discussed above, the dimensions of channel 72 are configured toconform the melt flow of the molten material of ribbon filament 44 to anarcuate-patterned flow, which is a type of axially-asymmetric flow.However, as shown in FIG. 5, the dimensions of extrusion tip 52 andconical tip 94 provide dimensions that change the melt flow from thearcuate-patterned flow to an axially-symmetric flow for extrusion fromextrusion tip 52. This is in contrast to a cylindrical liquefier, inwhich a melt flow remains as an axially-symmetric flow in thecylindrical liquefier and in the extrusion tip.

FIG. 6 is a side view of ribbon liquefier 38 in use with pulley 58 ofdrive mechanism 42 (shown in FIG. 2) for melting and extruding materialof ribbon filament 44 to build 3D model 24 (or alternatively supportstructure 26, shown in FIG. 1). Thermal block 40, and support plate 54and base block 56 of drive mechanism 42 are omitted in FIG. 6 for easeof discussion. As shown, pulley 58 includes inner surface 98, which isthe internally-threaded surface of pulley 58 and is engaged with ribbonfilament 44 at port 76. Examples of suitable internally-threadedsurfaces for inner surface 98 are disclosed in Batchelder et al., U.S.Pat. Nos. 7,896,209 and 7,897,074.

During the build operation to form 3D model 24, ribbon filament 44 isloaded into channel 72 of liquefier 38 at top end 48. As discussedabove, ribbon filament is desirably flexed to have a bowed cross-sectionthat substantially aligns with the arcuate cross-section of channel 72.In one embodiment, ribbon filament 44 may be in a relaxed, non-flexedstate while in supply source 20 (shown in FIG. 1) and while being fedthrough pathway 34 (shown in FIG. 1). Upon reaching top end 48 of ribbonliquefier 38, ribbon filament 42 may be flexed (e.g., manually flexed)to the desired bowed cross-section and fed into channel 72. Assuccessive portions of ribbon filament 44 are pulled into channel 72,the arcuate cross-section of channel 72 may cause successive portions ofribbon filament 44 to automatically flex and conform the dimensions ofchannel 72.

The rotation of pulley 58 allows inner surface 98 to drive successiveportions of ribbon filament 44 downward along longitudinal axis 46through channel 72 toward heated length 78. While passing throughchannel 72 at heated length 78, the thermal gradient generated bythermal block 40 (shown in FIG. 2) melts the material of ribbon filament44 to an extrudable state. The unmelted, successive portion of ribbonfilament 44, located upstream from heated length 78, is driven by pulley58 and inner surface 98, and functions as a piston with a viscosity pumpacting on the molten material between the unmelted portion and channel72, thereby extruding the molten material of ribbon filament 44 throughextrusion tip 52. As discussed above, the cross-sectional dimensions ofchannel 72, particularly those in the above-discussed suitable aspectratio ranges, allow the material of ribbon filament 44 to be extrudedwith reduced response times. The extruded material is then deposited asroads to build 3D model 24 in a layer-by-layer manner.

As also discussed above, inlet region 64 is located at an upstreamposition along longitudinal axis 46 relative to pulley 58. As such,ribbon filament 44 enters channel 72 prior to engaging with innersurface 98, and is continuously supported by exterior surface 84 of coretube 68 (shown in FIGS. 3-5) during and after the engagement with innersurface 98. This effectively eliminates the potential issues that mayoccur with extrusion heads having separate drive mechanisms andliquefiers (e.g., alignment and buckling), thereby reducing the risk ofinterrupting a build operation with extrusion head 18 (shown in FIG. 1).

FIG. 7 is a side view of liquefier tube 32 in use with rotatable shaft100 of an alternative filament drive mechanism for melting and extrudingmaterial of ribbon filament 44 to build 3D model 24. Thermal block 40(shown in FIG. 2) is omitted in FIG. 7 for ease of discussion. In thisembodiment, rotatable shaft 100 includes threaded surface 102, which isan externally-threaded surface engaged with ribbon filament 44 at port76. The rotation of rotatable shaft 100 allows threaded surface 102 todrive successive portions of ribbon filament 44 downward alonglongitudinal axis 46 through channel 72 toward heated length 78. Thematerial of ribbon filament 44 is then melted in channel 72 at heatedlength 78, thereby allowing the molten material to be extruded fromextrusion tip 52 to build 3D model 24 in a layer-by-layer manner.

In this embodiment, inlet region 64 is also located at an upstreamposition along longitudinal axis 46 relative to threaded surface 102. Assuch, ribbon filament 44 enters channel 72 prior to engaging withthreaded surface 102, and is continuously supported exterior surface 84of core tube 68 (shown in FIGS. 3-5) during and after the engagementwith threaded surface 102. This effectively eliminates the potentialissues that may occur with extrusion heads having separate drivemechanisms and liquefiers (e.g., alignment and buckling). Accordingly,ribbon liquefier 38 is suitable for use with a variety of differentdrive mechanisms, where the drive mechanisms may engage ribbon filament44 after ribbon filament 44 is supported by core tube 68 (e.g., at port76).

FIGS. 8A and 8B are sectional views of ribbon filament 44 taken in aplane that is perpendicular to longitudinal axis 46 (shown in FIG. 2),where FIG. 8A depicts ribbon filament 44 in a relaxed, non-flexed stateand FIG. 8B depicts ribbon filament 44 in a flexed state. As shown inFIG. 8A, ribbon filament 44 has width 104 and thickness 106, whichgenerally correspond to channel thickness 88 and the arcuate width ofchannel 72 (shown in FIG. 4A). Ribbon filament 44 also has a continuouslength that may vary depending on the amount of ribbon filament 44remaining in supply source 20 (shown in FIG. 1).

Width 104 may vary depending on the dimensions of channel 72 and on howfar ribbon filament 44 is flexed. Examples of suitable dimensions forwidth 104 range from about 1.0 millimeter (about 0.04 inches) to about10.2 millimeters (about 0.40 inches), with particularly suitable widthsranging from about 2.5 millimeters (about 0.10 inches) to about 7.6millimeters (about 0.30 inches), and with even more particularlysuitable widths ranging from about 3.0 millimeters (about 0.12 inches)to about 5.1 millimeters (about 0.20 inches).

Suitable dimensions for thickness 106 desirably allow ribbon filament 44to be inserted into channel 72 while in a flexed state. For example,thickness 106 is desirably low enough to allow ribbon filament 44 toaxially flex to the flexed state (as represented by arrows 108) and tobend along its length to wind ribbon filament 44 in supply source 20 andto feed ribbon filament 44 through pathway 34 (shown in FIG. 1). Forexample, in one embodiment, ribbon filament 44 is desirably capable ofwithstanding elastic strains greater than t/r, where “t” is across-sectional thickness of ribbon filament 44 in the plane ofcurvature (e.g., thickness 106), and “r” is a bend radius (e.g., a bendradius in supply source 20 or 22 and/or a bend radius through pathway 34or 36).

Thickness 106 is desirably thick enough to provide a suitable structuralintegrity for ribbon filament 44, thereby reducing the risk of fracturesor breaks while ribbon filament 44 is retained in supply source 20 or 22and while being fed through system 10 (e.g., through pathways 30 or 32).Examples of suitable dimensions for thickness 106 range from about 0.08millimeters (about 0.003 inches) to about 1.5 millimeters (about 0.06inches), with particularly suitable thicknesses ranging from about 0.38millimeters (about 0.015 inches) to about 1.3 millimeters (about 0.05inches), and with even more particularly suitable thicknesses rangingfrom about 0.51 millimeters (about 0.02 inches) to about 1.0 millimeters(about 0.04 inches).

Ribbon filament 44 also desirably has an aspect ratio of width 104 tothickness 106 that substantially corresponds to the aspect ratio ofchannel 72 at top end 48 when ribbon filament 42 is flexed for alignmentwith channel 72, as shown in FIG. 8B. Examples of suitable aspect ratiosof width 104 to thickness 106 include aspect ratios of about 2:1 orgreater, with particularly suitable aspect ratios ranging from about2.5:1 to about 20:1, with even more particularly suitable aspect ratiosranging from about 3:1 to about 10:1, and with even more particularlysuitable aspect ratios ranging from about 3:1 to about 8:1.

Ribbon filament 44 may be manufactured from a variety of extrudablemodeling and support materials for respectively building 3D model 24 andsupport structure 26 (shown in FIG. 1). Suitable modeling materials forribbon filament 44 include polymeric and metallic materials. In someembodiments, suitable modeling materials include materials havingamorphous properties, such as thermoplastic materials, amorphousmetallic materials, and combinations thereof. Examples of suitablethermoplastic materials for ribbon filament 44 includeacrylonitrile-butadiene-styrene (ABS) copolymers, polycarbonates,polysulfones, polyethersulfones, polyphenylsulfones, polyetherimides,amorphous polyamides, modified variations thereof (e.g., ABS-M30copolymers), polystyrene, and blends thereof. Examples of suitableamorphous metallic materials include those disclosed in Batchelder, U.S.Pat. No. 8,215,371.

Suitable support materials for ribbon filament 44 include materialshaving amorphous properties (e.g., thermoplastic materials) and that aredesirably removable from the corresponding modeling materials after 3Dmodel 24 and support structure 26 are built. Examples of suitablesupport materials for ribbon filament 44 include water-soluble supportmaterials commercially available under the trade designations“WATERWORKS” and “SOLUBLE SUPPORTS” from Stratasys, Inc., Eden Prairie,Minn.; break-away support materials commercially available under thetrade designation “BASS” from Stratasys, Inc., Eden Prairie, Minn., andthose disclosed in Crump et al., U.S. Pat. No. 5,503,785; Lombardi etal., U.S. Pat. Nos. 6,070,107 and 6,228,923; Priedeman et al., U.S. Pat.No. 6,790,403; and Hopkins et al., U.S. Pat. No. 8,246,888.

The composition of ribbon filament 44 may also include additionaladditives, such as plasticizers, rheology modifiers, inert fillers,colorants, stabilizers, and combinations thereof. Examples of suitableadditional plasticizers for use in the support material include dialkylphthalates, cycloalkyl phthalates, benzyl and aryl phthalates, alkoxyphthalates, alkyl/aryl phosphates, polyglycol esters, adipate esters,citrate esters, esters of glycerin, and combinations thereof. Examplesof suitable inert fillers include calcium carbonate, magnesiumcarbonate, glass spheres, graphite, carbon black, carbon fiber, glassfiber, talc, wollastonite, mica, alumina, silica, kaolin, siliconcarbide, composite materials (e.g., spherical and filamentary compositematerials), and combinations thereof. In embodiments in which thecomposition includes additional additives, examples of suitable combinedconcentrations of the additional additives in the composition range fromabout 1% by weight to about 10% by weight, with particularly suitableconcentrations ranging from about 1% by weight to about 5% by weight,based on the entire weight of the composition.

Ribbon filament 44 also desirably exhibits physical properties thatallow ribbon filament 44 to be used as a consumable material in system10. In one embodiment, the composition of ribbon filament 44 issubstantially homogenous along its length. Additionally, the compositionof ribbon filament 44 desirably exhibits a glass transition temperaturethat is suitable for use in build chamber 12. Examples of suitable glasstransition temperatures at atmospheric pressure for the composition ofribbon filament 44 include temperatures of about 80° C. or greater. Insome embodiments, suitable glass transition temperatures include about100° C. or greater. In additional embodiments, suitable glass transitiontemperatures include about 120° C. or greater.

Ribbon filament 44 also desirably exhibits low compressibility such thatits axial compression doesn't cause ribbon filament 44 to be seizedwithin a liquefier. Examples of suitable Young's modulus values for thepolymeric compositions of ribbon filament 44 include modulus values ofabout 0.2 gigapascals (GPa) (about 30,000 pounds-per-square inch (psi))or greater, where the Young's modulus values are measured pursuant toASTM D638-08. In some embodiments, suitable Young's modulus range fromabout 1.0 GPa (about 145,000 psi) to about 5.0 GPa (about 725,000 psi).In additional embodiments, suitable Young's modulus values range fromabout 1.5 GPa (about 200,000 psi) to about 3.0 GPa (about 440,000 psi).

Additional examples of suitable ribbon filament for ribbon filament 44and suitable techniques for manufacturing ribbon filament 44 includethose disclosed in U.S. Pat. No. 8,221,669; and ribbon filaments havingtopographical surface patterns as disclosed in U.S. Pat. No. 8,236,227.

FIGS. 9 and 10 illustrate examples of suitable alternative ribbonliquefiers to ribbon liquefier 38 (shown in FIGS. 2-7), where theabove-discussed embodiments are equally applicable to the followingexamples. As shown in FIG. 9, ribbon liquefier 138 is a firstalternative to ribbon liquefier 38, where the corresponding referencelabels are increased by “100”. In this embodiment, the inlet region andport corresponding to inlet region 64 and port 76 are omitted. Instead,core tube 168 extends beyond outer tube 166 and shim component 170 attop end 148. In this embodiment, a drive mechanism (e.g., drivemechanism 42) may engage ribbon filament 44 at outer surface 184 of coretube 168, above channel 172. This allows the drive mechanism to drivesuccessive portions of ribbon filament 44 into channel 172 while outersurface 184 functions as a lateral backing support for ribbon filament44 in the same manner as discussed above for ribbon liquefier 38.

In the shown embodiment, suitable dimensions for heated length 178 toexist, between the entrance of channel 172 and bottom end 150 (referredto as length 182), may also vary depending on the heat transferproperties of thermal block 40 (shown in FIG. 2), the thickness andmaterial of outer tube 166, and the thickness, material, and drive rateof ribbon filament 44. Examples of suitable lengths for length 182include those discussed above for length 82 (shown in FIG. 3).

In an alternative embodiment, shim component 170 may also extend upwardwith core tube 168. In additional alternative embodiments, one or moreof outer tube 166, core tube 168, and shim component 170 may include astrain gauge, as discussed in Batchelder et al., U.S. Pat. No.7,897,074. This is beneficial for monitoring the loads applied to outertube 166, core tube 168, and/or shim component 170 during operation insystem 10.

FIG. 10 is a sectional view of ribbon liquefier 238, which is anadditional alternative to ribbon liquefier 38 (shown in FIGS. 2-7) andribbon liquefier 138 (shown in FIG. 9). The sectional view correspondsto section 4A-4A taken in FIG. 3, and the corresponding reference labelsare increased by “200”. As shown, ribbon liquefier 238 includes outertube 266, core portion 268, and shim component 270, which define channel272, where channel 272 has a rectangular cross-section rather than anarcuate cross-section.

Suitable dimensions for outer tube 266, core portion 268, shim component270, and channel 272 include those discussed above for the respectivecomponents of ribbon liquefier 38. For example, suitable average widthsfor exterior surface 274 (referred to as width 274 w), exterior surface284 (referred to as width 284 w), and interior surface 286 (referred toas width 286 w) include those discussed above for outer diameter 74 d,outer diameter 84 d, and inner diameter 86 d (shown in FIG. 4A),respectively. The dimensions of outer tube 266, core portion 268, andshim component 270 may be substantially the same along the x-axis andthe y-axis (i.e., a square cross-section as shown in FIG. 10), or may bedifferent (e.g., rectangular) depending on the particular design ofribbon liquefier 238. Correspondingly, suitable widths for channel 272(referred to as width 272 w) include those discussed above for thearcuate width of channel 72, and suitable thicknesses for channel 272(referred to as thickness 272 t) include those discussed above forthickness 88 (shown in FIG. 4A).

In the shown embodiment, core portion 268 is filled rather than having ahollow bore region. This is beneficial for ensuring that core portion268 can withstand the lateral stresses applied to outer surface 284 froma drive mechanism (e.g., drive mechanism 42, shown in FIG. 2) withoutbuckling or deforming. In an alternative embodiment, core portion 268may be a hollow core tube having a suitable wall thickness.

Ribbon liquefier 238 is an example of a suitable ribbon liquefier of thepresent disclosure that is configured to receive ribbon filament 44 in arelaxed, non-flexed state, as shown above in FIG. 8A. The dimensions ofribbon liquefier 238 and ribbon filament 44 also effectively remove thecore that is associated with a cylindrical filament having a circularcross-section. This allows the ribbon liquefier 238 to also attainreduced response times compared to cylindrical liquefiers having thesame volumetric flow rates.

Additionally, the dimensions of channel 272 are configured to conformthe melt flow of the molten material of ribbon filament 44 to arectangular-patterned flow, which is also an axially-asymmetric flow.Upon reaching extrusion tip 252 (not shown), however, this melt flowchanges to a substantially axially-symmetric flow for extrusion in thesame manner as discussed above for ribbon liquefier 38 in FIG. 5. Thisis also in contrast to a cylindrical liquefier, in which a melt flowremains as an axially-symmetric flow in the cylindrical liquefier and inthe extrusion tip.

In additional embodiments of the present disclosure, the above-discussedcylindrical and non-cylindrical filaments may also be hollow. Since thecross-sectional area of the plastic is reduced by the missing core, thehydraulic diameter of the hollow filament may also be less than thephysical diameter. Accordingly, examples of suitable hydraulic diametersfor the hollow filaments of the present disclosure include thosediscussed above. Furthermore, the liquefier may also include a matingcore to the hollow filament, so that the extrudate is heated from theinside as well as the outside.

One potential additional advantage of a hollow filament is that whenhollow filament is manufactured by rapid extrusion from a compounder, itis desirably rapidly cooled before it is retained on a supply assembly(e.g., spooled). That rapid cooling process may induce diameter changesin an otherwise solid filament that may vary along its length. Incomparison, if a hollow filament is rapidly cooled, the inner surface ofthe hollow filament can vary in diameter, leaving the outer surface moreuniform.

Another potential additional advantage of a hollow filament in the formof a cylindrical shell is compliance with the filament drive mechanism.A solid filament may be close to incompressible, so that a drive rolleror drive teeth may obtain too little or too much traction if thefilament diameter is slightly small or large. A hollow filament,however, provides compliance so that small variations in the filamentdiameter are compensated by variations in the amount of compression ofthe hollow filament.

Yet another potential additional advantage of a hollow filament is thereduced thermal conduction in the inlet of the liquefier. When a solidfilament is stationary, heat may slowly conduct up the center of thefilament to the zone above the heated portion of the liquefier where thewalls are relatively cool. If the filament melts there, it tends tosolidify against the cooler wall, potentially causing a large axialforce to restart filament motion. The rate of heat conduction up ahollow filament, however, will be slower than the rate of conduction upa solid filament due to the lack of a core.

Although the present disclosure has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the disclosure.

The invention claimed is:
 1. A method for building a three-dimensionalmodel in an extrusion-based additive manufacturing system, the methodcomprising: heating a liquefier retained by the extrusion-based digitalmanufacturing system, the liquefier having a non-cylindrical staticchannel with an inlet end and an outlet end; feeding a non-cylindricalfilament into the inlet end of the static channel of the heatedliquefier; melting the non-cylindrical filament in the static channel toat least an extrudable state with the heat to provide a molten material;moving the molten material from the non-cylindrical static channel to anextrusion tip disposed at the outlet end of the channel with aviscosity-pump action of the fed non-cylindrical filament wherein theextrusion tip has a substantially circular cross-section; extruding themolten material from the extrusion tip; and depositing the extrudedmaterial as a road to form at least a portion of a layer of thethree-dimensional model.
 2. The method of claim 1, wherein thenon-cylindrical static channel comprises a substantially-rectangularcross section substantially perpendicular along an axis extending fromthe inlet end to the outlet end.
 3. The method of claim 2, wherein thesubstantially-rectangular cross section has a width and a thickness,wherein an aspect ratio of the width to the thickness is about 2:1 orgreater.
 4. The method of claim 2, wherein aspect ratio of the width tothe thickness ranges from 2.5:1 to about 20:1.
 5. The method of claim 1,wherein the static channel extends along an axis from the inlet end tothe outlet end and has a partial annular cross section perpendicular tothe axis.
 6. The method of claim 1, wherein feeding the non-cylindricalfilament into the inlet end of the static channel comprises driving thenon-cylindrical filament into the inlet end of the static channel with afilament drive mechanism.
 7. The method of claim 1, wherein thenon-cylindrical filament comprises topographical surface patterns. 8.The method of claim 1, wherein melting the non-cylindrical filament inthe static channel comprises transferring the heat as thermal energy tothe non-cylindrical filament in the static channel in a manner such thatat least about 60% of the transferred thermal energy diffuses throughthe non-cylindrical filament in one cross-sectional dimension of thenon-cylindrical filament.
 9. A method for building a three-dimensionalmodel in an extrusion-based additive manufacturing system, the methodcomprising: providing a non-cylindrical filament to an extrusion headretained by the extrusion-based additive manufacturing system, whereinthe extrusion head comprises a liquefier tube with a non-cylindricalstatic channel, a heat transfer component coupled in thermalcommunication with the liquefier tube, and an extrusion tip having anexit port; transferring thermal energy from the heat transfer componentto at least a portion of the liquefier tube; feeding the non-cylindricalfilament into an inlet end of the non-cylindrical static channel of theliquefier tube; melting the non-cylindrical filament in the staticchannel to at least an extrudable state with the transferred thermalenergy to provide a molten material; conforming the molten material todimensions of the static channel; moving the molten material to anextrusion tip of the extrusion head with a viscosity-pump action of thefed non-cylindrical filament; extruding the melt flow from the extrusiontip; and depositing the extruded material as a road to form at least aportion of a layer of the three-dimensional model.
 10. The method ofclaim 9, non-cylindrical static channel comprises asubstantially-rectangular cross section substantially perpendicularalong an axis extending from the inlet end to the outlet end.
 11. Themethod of claim 10, wherein an aspect ratio of thesubstantially-rectangular cross section of the static channel is about2:1 or greater.
 12. The method of claim 11, wherein the extrusion headfurther comprises a filament drive mechanism, and wherein feeding thenon-cylindrical filament into the inlet end of the static channelcomprises driving the non-cylindrical filament into the inlet end of thestatic channel with the filament drive mechanism.
 13. The method ofclaim 11, wherein at least a portion of the non-cylindrical staticchannel comprises a layer of a fluorinated polymer.
 14. A method forbuilding a three-dimensional model in an extrusion-based digitalmanufacturing system, the method comprising: providing thermal energy toa liquefier having a liquefier tube with a non-cylindrical static flowchannel extending from an inlet end to an outlet end, the liquefier tuberetained by the extrusion-based digital manufacturing system; feedingsuccessive segments of a non-cylindrical filament from a supply sourceto the inlet end of the static channel of the liquefier tube, whereinthe supply source is spaced from the liquefier; transferring theprovided thermal energy to the successive segments of thenon-cylindrical filament in the static channel in a manner such that atleast about 60% of the transferred thermal energy diffuses through thenon-cylindrical filament in one cross-sectional dimension of thenon-cylindrical filament to melt the successive segments of thenon-cylindrical filament to produce a molten material; moving the moltenmaterial from the static channel to an extrusion tip disposed at theoutlet end of the static channel with a viscosity-pump action ofunmelted segments of the fed non-cylindrical filament; extruding themolten material from the extrusion tip; and depositing the extrudedmaterial as a road to form at least a portion of a layer of thethree-dimensional model.
 15. The method of claim 14, wherein thenon-cylindrical static channel comprises a substantially-rectangularcross section substantially perpendicular along an axis extending fromthe inlet end to the outlet end.
 16. The method of claim 15, wherein thesubstantially-rectangular cross section has a width and a thickness,wherein an aspect ratio of the width to the thickness is about 2:1 orgreater.
 17. The method of claim 15, wherein at least about 65% of thetransferred thermal energy diffuses through the non-cylindrical filamentin the one cross-sectional dimension of the non-cylindrical filament.18. The method of claim 17, wherein at least about 70% of thetransferred thermal energy diffuses through the non-cylindrical filamentin the one cross-sectional dimension of the non-cylindrical filament.19. The method of claim 15, wherein feeding the successive segments ofthe non-cylindrical filament into the inlet end of the static channelcomprises driving the successive segments of the non-cylindricalfilament into the inlet end of the static channel with a filament drivemechanism.
 20. The method of claim 15, wherein the static channelextends along an axis from the inlet end to the outlet end and has apartial annular cross section perpendicular to the axis.